Reel with rolled core

Abstract

A kit for assembly into at least a first reel includes a core and two flanges. The core has a substantially rectangular main body having opposing first and second axially extending edges and opposing first and second end edges extending between the first and second axially extending edges. The core also includes a first set of interlocking teeth on the first axially extending edge, and a first set of first connecting tabs on the first end edge. The main body is configured to be deformed or rolled into a cylinder in which the first set of interlocking teeth engage connecting features of the second axially extending edge. The first flange has an annulus and at least one axially extending rib or rim. The annulus includes receptacles for receiving and operably coupling to the first set of connecting tabs. The second flange is configured to couple to the core.

What is claimed is: 
     
         1 . A kit configured for assembly into at least a first reel, the kit comprising:
 a core having a substantially rectangular main body having opposing first and second axially extending edges and opposing first and second end edges extending between the first and second axially extending edges, a first set of interlocking teeth on the first axially extending edge, a first set of first connecting tabs on the first end edge, the main body configured to be deformed or rolled into a cylinder in which the first set of interlocking teeth engage connecting features of the second axially extending edge;   a first flange having an annulus and at least one axially extending-rib or rim, the annulus including receptacles for receiving and operably coupling to the first set of connecting tabs to axially retain a first side of the annulus on the core while an end point of each of the first set of connecting tabs stands proud of a second side of the annulus; and   a second flange configured to couple to the core when the main body is rolled into a cylinder.   
     
     
         2 . The kit of  claim 1 , further comprising a plurality of other cores, each other core having a substantially rectangular main body having opposing first and second axially extending edges and opposing first and second end edges extending between the first and second axially extending edges, a first set of interlocking teeth on the first axially extending edge, a first set of first connecting tabs on the first end edge, the main body configured to be deformed or rolled into a cylinder in which the first set of interlocking teeth engage connecting features of the second axially extending edge;
 a plurality of other first flanges, each other first flange having an annulus and at least one axially extending rib or rim, and including receptacles for receiving and operable coupling to the first set of connecting tabs of one of the other cores; and   a plurality of second flanges configured to couple to one of the other cores when the one of the other cores is rolled into a cylinder.   
     
     
         3 . The kit of  claim 2 , wherein the core and plurality of other cores are disposed on first shipping substrate, and the first flange and the plurality of other first flanges are disposed on a second shipping substrate. 
     
     
         4 . The kit of  claim 1 , wherein each of the connecting tabs includes a stem having a first end connected to main body, and a second end, and a retainer disposed at the second end of the stem, the retainer having a width greater than a greatest width of the stem. 
     
     
         5 . The kit of  claim 4 , wherein a first side of the retainer is coupled to the second end of the stem, and a second side that disposed further from the main body than the first side, and wherein the first side has a width that is greater than the second side to facilitate insertion into a corresponding one of the receptacles. 
     
     
         6 . The kit of  claim 4 , wherein the first end edge includes a plurality of recessed areas thar are recessed from other areas of the first end edge, and wherein the stem of each connecting tab is coupled to the first end edge in a corresponding one of the recessed areas. 
     
     
         7 . The kit of  claim 4 , wherein:
 each of the receptacles of the first flange has a base having a first width, and an interior portion having a second width that is less than the first width;   the bases of the receptacles are arranged in a substantially circular pattern having a first diameter;   the interior portions of the receptacles are arranged in a substantially circular pattern having a second diameter that is less than the first diameter;   when the main body is deformed or rolled into the cylinder in which the first set of interlocking teeth engage the connecting features, the connecting tabs are arranged in a substantially circular pattern having a third diameter that is greater than the second diameter.   
     
     
         8 . The kit of  claim 7 , wherein the width of each retainer is greater than the first width of the base. 
     
     
         9 . The kit of  claim 8 , wherein the stem of each connecting tab is elastically deformable. 
     
     
         10 . The kit of  claim 8 , wherein the interior portions have an arcuate shape. 
     
     
         11 . The kit of  claim 1 , further comprising at least a first fastener clip configured to secure a first connecting tab to the rim or rib of the first flange. 
     
     
         12 . The kit of  claim 11 , wherein the first clip includes a slot configured to align with a corresponding opening in the rim or rib of the first flange, and wherein the first clip is configured to extend through the slot and the corresponding opening to secure first connecting tab to the rim or rib of the first flange. 
     
     
         13 . The kit of  claim 1 , wherein the connecting features of the second axially extending edge comprises a second set of interlocking teeth. 
     
     
         14 . A reel for retaining wound flexible media, comprising:
 a core having a substantially rectangular main body having opposing first and second axially extending edges and opposing first and second end edges extending between the first and second axially extending edges, a first set of interlocking teeth on the first axially extending edge, a first set of first connecting tabs on the first end edge, the main body configured to be deformed or rolled into a cylinder in which the first set of interlocking teeth engage connecting features of the second axially extending edge;   a first flange having an annulus and at least one axially extending rib or rim, the annulus including receptacles for receiving and operably coupling to the first set of connecting tabs to axially retain a first side of the annulus on the core while an end point of each of the first set of connecting tabs stands proud of a second side of the annulus; and   a second flange coupled to the core.   
     
     
         15 . The reel of  claim 14 , wherein each of the connecting tabs includes a stem having a first end connected to main body, and a second end, and a retainer disposed at the second end of the stem, the retainer having a width greater than a greatest width of the stem. 
     
     
         16 . The reel of  claim 15 , wherein:
 each of the receptacles of the first flange has a base having a first width, and an interior portion having a second width that is less than the first width;   the bases of the receptacles are arranged in a substantially circular pattern having a first diameter;   the interior portions of the receptacles are arranged in a substantially circular pattern having a second diameter that is less than the first diameter;   when the main body is deformed or rolled into the cylinder in which the first set of interlocking teeth engage the connecting features of the second axially extending edge, the connecting tabs are arranged in a substantially circular pattern having a third diameter that is greater than the second diameter.   
     
     
         17 . The reel of  claim 16 , wherein the width of each retainer is greater than the first width of the base. 
     
     
         18 . The reel of  claim 14 , further comprising at least a first clip configured to secure a first connecting tab to the rim or rib of the first flange. 
     
     
         19 . A reel for retaining wound flexible media, comprising:
 a core having a substantially rectangular main body having opposing first and second axially extending edges and opposing first and second end edges extending between the first and second axially extending edges, a first set of interlocking teeth on the first axially extending edge, a first set of first connecting tabs on the first end edge, the main body configured to be deformed or rolled into a cylinder in which the first set of interlocking teeth engage connecting features of the second axially extending edge;   a first flange having an annulus and at least one rib or rim, the annulus including receptacles that receive and operably couple to the first set of connecting tabs such that at least a portion of the annulus disposed between the first end edge and at least one of the first set of connecting tabs; and   a second flange coupled to the core.